Print head alignment systems and methods for increasing print resolution

Abstract

Systems and methods for pre-aligning print head(s) to alignment adapter(s) to increase print resolution of printed matter, and to reduce offline time of a printing system due to print head alignment, include the use of an alignment adapter to which a print head is pre-aligned and which includes precision alignment features which precisely engage cooperating precision alignment features on the print head carriage mounting plate of the print head carriage. Print head(s) can be pre-aligned and fine-tuned to alignment adapter(s) even while the printing system is still in print production. Pre-aligned print head/alignment adapter assemblies can then be quickly mounted on the print head carriage using the cooperating precision alignment features of the adapter and print head carriage mounting plate. Duplicate sets of print head mounting sockets can include print heads aligned at different relative offsets (e.g., half a pixel) to increase the print resolution.

What is claimed is: 
     
         1 . A method for increasing resolution of printed matter to be printed using a printing system, the printing system configured with a print head carriage having a print head carriage mounting plate, the print head carriage mounting plate configured with a plurality of print head mounting sockets for receiving respective print heads therein, the print heads characterized by a native print resolution, the plurality of print head mounting sockets arranged on the print head carriage mounting plate in at least two parallel rows and wherein a first socket located in a first row and a second socket located in a second row of the print head carriage mounting plate are aligned in a column, the method comprising:
 mounting a first print head in a first socket of a first print head alignment adapter;   aligning the first print head within the first socket of the first print head alignment adapter so as to position the first print head to have a first alignment relative a predetermined feature of the first print head alignment adapter;   mounting a second print head in a second socket of a second print head alignment adapter;   aligning the second print head within the second socket of the second print head alignment adapter so as to position the second print head to have a second alignment relative the corresponding predetermined, feature of the second print head alignment adapter, the second alignment different than the first alignment;   mounting the first print head alignment adapter having the aligned print head mounted thereon to the first socket of a print head carriage mounting plate;   mounting the second print head alignment adapter having the aligned second print head mounted thereon to the second socket of the print head carriage mounting plate;   wherein the first alignment and the second alignment are configured so as to increase a print resolution of the printing system beyond the native print resolution of the print heads.   
     
     
         2 . The method of  claim 1 , wherein the first socket of the print head carriage mounting plate is identical to the second socket of the print head carriage mounting plate. 
     
     
         3 . The method of  claim 1 , wherein the first socket of the first print head alignment adapter is identical to the second socket of the second print head alignment adapter. 
     
     
         4 . The method of  claim 1 , wherein:
 the step of mounting the first print head alignment adapter to the first socket of a print head carriage mounting plate comprises kinematic coupling the first print head alignment adapter to the first socket of the print head carriage mounting plate, and   the step of mounting the second print head alignment adapter to the second socket of a print head carriage mounting plate comprises kinematic coupling the second print head alignment adapter to the second socket of the print head carriage mounting plate.   
     
     
         5 . The method of  claim 1 , wherein the first alignment is a first spatial offset and the second alignment is a second spatial offset different than the first spatial offset. 
     
     
         6 . The method of  claim 1 , wherein the first alignment is a first saber angle and the second alignment is a second saber angle different than the first saber angle. 
     
     
         7 . A print head carriage mounting plate for a print head carriage, the print head carriage mounting plate comprising:
 a plurality of print head mounting sockets for receiving respective print heads therein, the print heads characterized by a native print resolution, the plurality of print head mounting sockets arranged on the print head carriage mounting plate in at least two parallel and wherein a first print head mounting socket located in a first row and a second print head mounting socket located in a second row of the print head carriage mounting plate are aligned in a corresponding column on the print head carriage mounting plate;   a first print head alignment adapter to the first print head mounting socket of a print head carriage mounting plate, the first print head alignment adapter having a first alignment adapter socket and a first print head mounted in the first alignment adapter socket and aligned to a first alignment relative to a predetermined feature of the first alignment adapter;   a second print head alignment adapter to the second print head mounting socket of a print head carriage mounting plate, the second print head alignment adapter having a second alignment adapter socket and a second print head mounted in the second alignment adapter socket and aligned to a second alignment relative to a predetermined feature of the second alignment adapter;   wherein the first alignment and the second alignment are configured so as to increase a print resolution of the printing system beyond the native print resolution of the print heads.   
     
     
         8 . The print head carriage mounting plate of  claim 7 , wherein the first print head mounting socket is identical to the second print head mounting socket. 
     
     
         9 . The print head carriage mounting plate of  claim 7 , wherein the first socket of the first print head alignment adapter is identical to the second socket of the second print head alignment adapter. 
     
     
         10 . The print head carriage mounting plate of  claim 7 , wherein:
 the first print head alignment adapter is kinematic coupled, to the first print head mounting socket, and   the second print head alignment adapter is kinematic coupled to the second print head mounting socket.   
     
     
         11 . The print head carriage mounting plate of  claim 7 , wherein the first alignment is a first spatial offset and the second alignment is a second spatial offset different than the first spatial offset. 
     
     
         12 . The print head carriage mounting plate of  claim 7 , wherein the first alignment is a first saber angle and the second alignment is a second saber angle different than the first saber angle. 
     
     
         13 . A pre-aligned print head assembly, comprising:
 a first set of one or more print heads mounted on one or more first alignment adapters, the first set of print heads aligned, with a first offset, relative to a predetermined location on the respective one or more first alignment adapters;   a second set of one or more print heads mounted on one or more second alignment adapters, the second set of print heads aligned, with a second offset different than the first offset, relative to a predetermined location on the respective one or more second alignment adapters;   wherein the first offset and the second offset are less than a pixel in difference.   
     
     
         14 . The print head assembly of  claim 13 , wherein the difference between the first offset and the second offset is half a pixel in distance.